This is the accessible text file for GAO report number GAO-04-53 
entitled 'Defense Acquisitions: DOD's Revised Policy Emphasizes Best 
Practices, but More Controls Are Needed' which was released on November 
10, 2003.

This text file was formatted by the U.S. General Accounting Office 
(GAO) to be accessible to users with visual impairments, as part of a 
longer term project to improve GAO products' accessibility. Every 
attempt has been made to maintain the structural and data integrity of 
the original printed product. Accessibility features, such as text 
descriptions of tables, consecutively numbered footnotes placed at the 
end of the file, and the text of agency comment letters, are provided 
but may not exactly duplicate the presentation or format of the printed 
version. The portable document format (PDF) file is an exact electronic 
replica of the printed version. We welcome your feedback. Please E-mail 
your comments regarding the contents or accessibility features of this 
document to Webmaster@gao.gov.

This is a work of the U.S. government and is not subject to copyright 
protection in the United States. It may be reproduced and distributed 
in its entirety without further permission from GAO. Because this work 
may contain copyrighted images or other material, permission from the 
copyright holder may be necessary if you wish to reproduce this 
material separately.

Report to the Senate and House Committees on Armed Services:

United States General Accounting Office:

GAO:

November 2003:

Defense Acquisitions:

DOD's Revised Policy Emphasizes Best Practices, but More Controls Are 
Needed:

GAO-04-53:

GAO Highlights:

Highlights of GAO-04-53, a report to the Senate and House Committees 
on Armed Services 

Why GAO Did This Study:

The Department of Defense’s (DOD) investment in new weapon systems is 
expected to exceed $1 trillion from fiscal years 2003 to 2009. To 
reduce the risk of cost and schedule overruns, DOD revamped its 
acquisition policy in May 2003. The policy provides detailed guidance 
on how weapon systems acquisitions should be managed.

The Senate report accompanying the National Defense Authorization Act 
for Fiscal Year 2004 required GAO to determine whether DOD’s policy 
supports knowledge-based, evolutionary acquisitions and whether the 
policy provides the necessary controls for DOD to ensure successful 
outcomes, such as meeting cost and schedule goals.

The report also required GAO to assess whether the policy is 
responsive to certain requirements in the Bob Stump National Defense 
Authorization Act for Fiscal Year 2003 concerning DOD’s management of 
the acquisition process.

What GAO Found:

DOD’s new policy supports knowledge-based, evolutionary acquisitions 
by adopting lessons learned from successful commercial companies. One 
of those lessons is a knowledge-based approach, which requires program 
managers to attain the right knowledge at critical junctures—also 
known as knowledge points—so they can make informed investment 
decisions throughout the acquisition process. The policy also embraces 
an evolutionary or phased development approach, which sets up a more 
manageable environment for attaining knowledge. The customer may not 
get the ultimate capability right away, but the product is available 
sooner and at a lower cost. Leading firms have used these approaches—
which form the backbone of what GAO calls the best practices model—to 
determine whether a project can be accomplished with the time and 
money available and to reduce risks before moving a product to the 
next stage of development.

By adopting best practices in the acquisition policy, DOD’s leadership 
has taken a significant step forward. The next step is to provide the 
necessary controls to ensure a knowledge-based, evolutionary approach. 
Implementing the necessary controls at all three knowledge points 
along the acquisition process helps decision makers ensure a knowledge-
based approach is followed. Without controls in the form of measurable 
criteria that decision makers must consider, DOD runs the risk of 
making decisions based on overly optimistic assumptions. Each 
successive knowledge point builds on the preceding one, and having 
clearly established controls helps decision makers gauge progress in 
meeting goals and ensuring successful outcomes.

DOD was responsive to the requirements in the Bob Stump National 
Defense Authorization Act for Fiscal Year 2003. DOD’s responses 
reflected the committee’s specific concerns about the application of 
certain statutory and regulatory requirements to the new evolutionary 
acquisition process, for more guidance for implementing spiral 
development, and about technology readiness at program initiations.

What GAO Recommends:

GAO recommends that the Secretary of Defense strengthen DOD’s 
acquisition policy by requiring additional controls to ensure decision 
makers will follow a knowledge-based, evolutionary approach. DOD 
partially concurred with GAO’s recommendations.

www.gao.gov/cgi-bin/getrpt?GAO-04-53.

To view the full product, including the scope and methodology, click 
on the link above. For more information, contact Katherine V. Schinasi 
at (202) 512-4841 or schinasik@gao.gov.

[End of section]

Contents:

Letter:

Results in Brief:

Background:

DOD's Revised Policy Provides a Framework for Knowledge-Based, 
Evolutionary Acquisitions:

Controls Are Needed to Ensure Knowledge-Based Approach Is Followed:

DOD Is Responsive to Congressional Requirements about New Acquisition 
Process:

Conclusions:

Recommendations for Executive Action:

Agency Comments and Our Evaluation:

Scope and Methodology:

Appendix I: Section 802, Evolutionary Acquisition:

Appendix II: Section 803, Spiral Development:

Appendix III: Section 804, Technology Maturity, and Section 822, 
Independent Technology Readiness Assessments:

Appendix IV: Comments from the Department of Defense:

Related GAO Products:

Tables:

Table 1: Excerpts of Best Practices Contained in DOD's New Policy:

Table 2: Comparison of Controls Used in Best Practices Model and DOD 
Policy:

Table 3: How DOD Policy Addresses Section 802's Statutory and 
Regulatory Requirements:

Table 4: How DOD Responded to Section 802's Requirements Regarding 
Specific Matters for Each Increment of an Evolutionary Acquisition 
Process:

Table 5: How DOD Policy Addresses Section 803's Requirements:

Table 6: How DOD Responded to Section 804 and Section 822 Requirements:

Figures:

Figure 1: Distribution of Development Funds for Fiscal Year 2003:

Figure 2: Comparison of DOD's Framework and Commercial Best Practices 
Model:

Abbreviations:

DOD: Department of Defense:

DODDDOD Directive:

DODI: DOD Instruction:

MDA: Milestone Decision Authority:

TEMP: Test and Evaluation Master Plan:

United States General Accounting Office:

Washington, DC 20548:

November 10, 2003:

The Honorable John W. Warner: 
Chairman: 
The Honorable Carl Levin: 
Ranking Minority Member: 
Committee on Armed Services: 
United States Senate:

The Honorable Duncan Hunter: 
Chairman: 
The Honorable Ike Skelton: 
Ranking Minority Member: 
Committee on Armed Services: 
House of Representatives:

The Department of Defense (DOD) plans to spend more than $1†trillion 
from fiscal years 2003 to 2009 for developing and procuring weapon 
systems. To get the most out of its investment, DOD has set goals to 
develop and procure weapons faster and at less cost. Guiding this 
effort is DODís newly revised acquisition policy. Issued in May 2003, 
the policy seeks to foster greater efficiency while building 
flexibility in the acquisition process. The policy embraces a 
knowledge-based, evolutionary framework that emphasizes shorter 
development times.

DOD intends to use its policy to improve its record for meeting cost 
and schedule estimates and for delivering capabilities as promised. 
Congress has expressed support for DODís efforts to revamp its 
acquisition process and has established requirements that DOD must take 
to ensure a disciplined approach. Recognizing that a consistent and 
disciplined application of policies will be key to achieving desired 
outcomes, the Senate Armed Services Committe directed us to assess 
DOD's current acquisition policies to determine whether they (1) 
support knowledge-based, evolutionary acquisitions, (2) provide the 
necessary controls to ensure DOD's policy intent is followed, and (3) 
respond to specific requirements in the Bob Stump National Defense 
Authorization Act for Fiscal Year 2003 (Public Law 107-314) regarding 
DOD plans to manage its new acquisition process.[Footnote 1]e:

Results in Brief:

DOD has made major improvements to its acquisition policy by adopting 
knowledge-based, evolutionary practices used by successful commercial 
companies. If properly applied, these best practices can put DOD's 
decision makers in a better position to deliver high-quality products 
on time and within budget. The policy requires decision makers to have 
the knowledge they need before moving to the next phase of development. 
To ensure that the acquisition environment is conducive to a knowledge-
based approach, the policy embraces evolutionary development, which 
allows managers to develop a product in increments rather than trying 
to incorporate all the desired capabilities in the first version that 
comes off the production line. Leading companies who use the knowledge-
based evolutionary approach have shown that these best practices help 
reduce risks at critical junctures during a productís development and 
help ensure that decision makers get the most out of their investments.

DOD's recent policy changes are a significant step forward. The next 
step is for DOD to provide the necessary controls to ensure a 
knowledge-based, evolutionary approach is followed. For example, the 
policy does not establish measures to gauge design and manufacturing 
knowledge at critical junctures in the product development process. 
Without specific requirements to demonstrate knowledge at key points, 
the policy allows significant unknowns to be judged as acceptable 
risks, leaving an opening for decision makers to make uninformed 
decisions about continuing product development.

DOD was responsive to the requirements in the Defense Authorization Act 
for Fiscal Year 2003. DOD's responses reflected the committee's 
specific concerns about the application of certain statutory and 
regulatory requirements[Footnote 2] to the new evolutionary acquisition 
process, for more guidance for implementing spiral development, and 
about technology readiness at program initiations.

This report makes recommendations that the Secretary of Defense 
strengthen DOD's acquisition policy by requiring additional controls to 
ensure decision makers will follow a knowledge-based, evolutionary 
approach. DOD partially concurred with our recommendations. DOD 
believes the current acquisition framework includes the controls 
necessary to achieve effective results, but department officials will 
continue to monitor the process to determine whether other controls are 
needed to achieve the best possible outcomes. DOD agreed it should 
record and justify program decisions for moving from one stage of 
development to next but did not agree with the need to issue a report 
outside of the department.

Background:

Traditionally, DODís strategy for acquiring major weapon systems has 
been to plan programs that would achieve a big leap forward in 
capability. However, because the needed technologies often are not yet 
mature, programs stay in development for years until the technologies 
are demonstrated. As a result, weapon systems have frequentlybeen 
characterized by poor cost, schedule, and performance outcomes. This 
has slowed modernization efforts, reduced the buying power of the 
defense dollar, delayed capabilities for the warfighter, and forced 
unplanned--and possibly unnecessary--trade-offs among programs.

Our extensive body of work shows that leading companies use a product 
development model that helps reduce risks and increase knowledge when 
developing new products. This best practices model enables decision 
makers to be reasonably certain about their products at critical 
junctures during development and helps them make informed investment 
decisions. This knowledge-based process can be broken down into three 
cumulative knowledge points.

* Knowledge point 1: A match must be made between the customer's 
needs and the developer's available resources--technology, engineering 
knowledge, time, and funding--before a program starts.

* Knowledge point 2: The product's design must be stable and must 
meet performance requirements before initial manufacturing begins.

* Knowledge point 3: The product must be producible within cost, 
schedule, and quality targets and demonstrated to be reliable before 
production begins.

To bolster the knowledge-based process, leading companies use 
evolutionary product development, an incremental approach that enables 
developers to rely more on available resources rather than making 
promises about unproven technologies. While the user may not initially 
receive the ultimate capability under this approach, the initial 
product is available sooner and at a lower, more predictable cost. 
Also, leading companies know that invention cannot be scheduled and its 
cost is difficult to estimate. They do not bring technology into new 
product development unless that technology has been demonstrated to 
meet the user's requirements. Allowing technology development to spill 
over into product development puts an extra burden on decision makers 
and provides a weak foundation for making product development 
estimates.

DOD understands that it must improve acquisition process outcomes if 
it is to modernize its forces within currently projected resources. To 
help achieve this goal, DOD has revised its acquisition policy, called 
the 5000 series, to reflect best practices from successful commercial 
and DOD programs.[Footnote 3] The policy covers mostóbut not allmajor 
acquisitions. The Secretary of Defense has delegated authority to the 
Missile Defense Agency and to the National Security Space Team to 
develop separate guidance for missile defense and space systems, 
respectively.[Footnote 4] Approximately 35 percent of DOD's 
development funds in 2003 went to these systems. (Figure 1 shows how 
$43.1 billion in development funds were distributed across space, 
missile defense, and systems covered by the 5000 series.) This report 
addresses policy for the defense programs covered exclusively under the 
5000 series.ó:

Figure 1: Distribution of Development Funds for Fiscal Year 2003:

[See PDF for image]

Note: Includes research, development, test, and evaluation budget 
activities for advanced component development and prototypes; system 
development and demonstration; and operational systems development.

[End of figure]

DOD's Revised Policy Provides a Framework for Knowledge-Based, 
Evolutionary Acquisitions:

DOD's leaders have made significant improvements to DOD's acquisition 
policy by adopting the knowledge-based, evolutionary approach used by 
leading commercial companies. The revised policy has the potential to 
transform DODís acquisition process by reducing risks and increasing 
the chances for successful outcomes. The policy provides aframework for 
developers to ask themselves at key decision points whether they have 
the†knowledge they need to move to the next phase of acquisition. If 
rigorously applied, this knowledge-based framework can help managers 
gain the confidence they need to make significant and sound investment 
decisions for major weapon systems. In placing greater emphasis on 
evolutionary product development, the policy sets up a more manageable 
environment for achieving knowledge. Another best practice reflected in 
the policyís framework is separating technology development from 
product development, which reduces technological risk at the start of 
a program.

As shown in table 1, DODís policy emphasizes best practices used by 
leading companies.

Table 1: Excerpts of Best Practices Contained in DOD's New Policy:

Best practices: Knowledge-based acquisition; DOD policy: DOD Directive 
5000.1 (enclosure 1, p. 5): Program managers "shall provide knowledge 
about key aspects of a system at key points in the acquisition process. 
… shall reduce technology risk, demonstrate technologies in a relevant 
environment … prior to program initiation. They shall reduce 
integration risk and demonstrate product design prior to the design 
readiness review. They shall reduce manufacturing risk and demonstrate 
producibility prior to full-rate production.".

Best practices: Evolutionary acquisition; DOD policy: DOD Instruction 
5000.2 (p. 3): "Evolutionary acquisition is the preferred DOD strategy 
for rapid acquisition of mature technology for the user. … The 
objective is to balance needs and available capability with resources, 
and to put capability into the hands of the user quickly. The success 
of the strategy depends on consistent and continuous definition of 
requirements, and the maturation of technologies … that provide 
increasing capability towards a materiel concept.".

Best practices: Separating technology development from product 
development; DOD policy: DOD Instruction 5000.2 (p. 6): "The project 
shall exit Technology Development when an affordable increment of 
militarily-useful capability has been identified, the technology for 
that increment has been demonstrated in a relevant environment, and a 
system can be developed for production within a short timeframe 
(normally less than five years).".

Source: DOD.

[End of table]

Similar to the best practices model, DOD's policy divides its 
acquisition process into phases, as shown in figure 2. Key decisions 
are aligned with the three critical junctures of a productís 
development, or knowledge points.

Figure 2: Comparison of DOD's Framework and Commercial Best Practices 
Model:

[See PDF for image]

[End of figure]

In other similarities, DODís framework pinpoints program start at 
milestone B, about the same point as program start on the best 
practices model. At the midway point on both approaches, a stable 
product design should be demonstrated. With DODís framework, managers 
are required to knowóby the time full-rate production decision review 
occursówhether the product can be produced within cost, schedule, and 
quality targets. This requirement occurs earlier in the best practices 
model, before production begins, or at knowledge point 3. Leading 
companies have used†this approach to reduce risks and to make costs and 
delivery dates more predictable.

Controls Are Needed to Ensure Knowledge-Based Approach Is Followed:

While DOD has strengthened its acquisition policy with a knowledge-
based, evolutionary framework, the policy does not include many of the 
same controls that leading companies rely on to attain a high level of 
knowledge before making additional significant investments. Controls 
are considered effective if they are backed by measurable criteria and 
if decision makers are required to consider them before deciding to 
advance a program to the next level. Controls used by leading companies 
help decision makers gauge progress in meeting cost, schedule, and 
performance goals and ensure that managers will (1) conduct activities 
to capture relevant product development knowledge, (2) provide evidence 
that knowledge was captured, and (3) hold decision reviews to determine 
that appropriate knowledge was captured to move to the next phase.

To determine if DOD has the necessary controls, we compared controls in 
DOD's policy with those used in the best practices model at three 
critical junctures. Table 2 shows the presence or absence of controls 
for various versions of DOD policy since 1996, including the May 2003 
revision.

Table 2: Comparison of Controls Used in Best Practices Model and DOD 
Policy:

[See PDF for image]

Sources: GAO and DOD.

[End of table]

At all three knowledge points, DOD's policy does not provide all the 
necessary controls used by commercial companies. For example, at 
program launch (milestone B) or when knowledge point 1 should be 
reached, the policy requires decision makers to identify and validate a 
weapon system's key performance requirements and to have a technical 
solution for the system before program start. This information is then 
used to form cost and schedule estimates for the product's development. 
However, the policy does not emphasize the use of a disciplined systems 
engineering process for balancing a customer's needs with resources to 
deliver a preliminary design. The lack of effective controls at 
knowledge point 1 could result in gaps between requirements and 
resources being discovered later in development.

At the design readiness review or when knowledge point 2 should be 
reached, DOD's policy does not require specific controls to document 
that a product is ready for initial manufacturing and demonstration. 
DOD's policy suggests appropriate criteria, such as number of subsystem 
and system design reviews completed, percentage of drawings completed, 
planned corrective actions to hardware and software deficiencies, 
adequate development testing, completed failure modes and effects 
analysis, identification of key system characteristics and critical 
manufacturing processes, and availability of reliability targets and 
growth plans. However, these criteria are not required. For example, we 
found that a key indicator of a product's design stability is the 
completion of 90 percent of the engineering drawings supported by 
design reviews. DOD's policy does not require that a certain percentage 
of drawings or design reviews be completed to ensure the design is 
mature enough to enter the system demonstration phase. As a result, a 
decision maker has no benchmark to consider when deciding to advance a 
program to the next level of development.

Finally, at production commitment or when knowledge point 3 should be 
reached, DOD's policy does not require specific controls to document 
that a product can be manufactured to meet cost, schedule, and quality 
targets before moving into production. For example, the policy states 
there should be "no significant manufacturing risks" at the start of 
low-rate production but does not define what this means or how it is to 
be measured. DOD's policy does not require the demonstrated control of 
manufacturing processes and the collection of statistical process 
control data until full-rate production begins but even then fails to 
specify a measurable control. Given that low-rate production can last 
several years, a significant number of products can be manufactured 
before processes are brought under control, creating a higher 
probability of poor cost and schedule outcomes.

DOD Is Responsive to Congressional Requirements about New Acquisition 
Process:

While supporting efforts to build more flexibility into the DOD 
acquisition process and to develop weapon systems using an evolutionary 
approach, Congress asked DOD to be more disciplined in its approach. 
The Defense Authorization Act for Fiscal Year 2003 required DOD to 
address (1) the way it plans to meet certain statutory and regulatory 
requirements for managing its major acquisition programs, (2) needed 
guidance for implementing spiral developments, and (3) technology 
readiness (at acquisition program initiation). DOD was responsive to 
all three requirements. With regard to the second requirement, a 
description of the process that would be used to independently validate 
that measurable exit criteria for applying a spiral development 
process[Footnote 5] have been met was unclear. DOD stated that the 
milestone decision authority[Footnote 6] provides that independent 
validation as part of DOD's milestone approval process. DOD's responses 
to the relevant sections of the act are summarized below. More detailed 
comparisons are provided in appendixes I, II, and III.

Section 802: Evolutionary Acquisition:

Requirements: This section directed DOD to report on its plan to meet 
certain statutory and regulatory requirements for managing its major 
acquisition programs applying an evolutionary acquisition process. 
These include establishing and approving operational requirements and 
cost and schedule goals for each increment, meeting requirements for 
operational and live fire testing for each increment, and optimizing 
total system performance and minimizing total ownership costs.

DOD response: In April 2003, DOD submitted its report reflecting how 
these requirements are addressed in its acquisition policy. According 
to the report, the policy addresses the statutory and other 
requirements applicable to all major defense acquisition programs, 
including each increment of evolutionary acquisition programs. For 
example, the policy requires that each program or increment of an 
evolutionary acquisition have a milestone B decision to approve program 
initiation and to permit entry into system development and 
demonstration. The policy specifies the statutory and regulatory 
information necessary to support the decision.

Section 803: Spiral Development:

Requirements: This section authorizes DOD to conduct a research and 
development program for a major defense acquisition program using 
spiral development only if approved by the Secretary of Defense or 
authorized high-level designee.[Footnote 7] A program cannot be 
conducted as a spiral development unless the Secretary of Defense or 
designee approves a plan that describes such things as the program 
strategy, test plans, performance parameters, and measurable exit 
criteria. The section also requires the Secretary of Defense to issue 
guidance addressing the appropriate processes for an independent 
validation that exit criteria have been met, the operational assessment 
of fieldable prototypes, and the management of these types of programs. 
It further requires the Secretary to report to Congress on the status 
of each program applying spiral development by September 30 of each 
year from 2003 to 2008.

DOD response: DOD established a technology development strategy in the 
new policy to address this requirement. The strategy must be completed 
before a program can enter the technology development phase. The 
strategy also documents the cost and schedule goals, the test plans, 
the number of prototypes, and a program strategy for the total research 
and development program. The strategy requires a test plan to ensure 
the goals and exit criteria for the first technology spiral 
demonstration are met, and the policy requires an independent 
operational assessment for the release of each product increment to the 
user. What is unclear in DOD's guidance is the process that will be 
used for independently validating whether measurable cost, schedule, 
and performance exit criteria have been met. However, DOD stated that 
the milestone decision authority provides independent validation that 
exit criteria have been met as part of DOD's milestone approval 
process. As of October 23, 2003, DOD's report on the status of each 
program applying spiral development was still in draft and not yet 
submitted. DOD's current draft report states that there are no research 
and development programs that have been approved as spiral development 
programs as of September 30, 2003. Section 803 requirements were 
implemented in DOD Instruction 5000.2, which was effective in May 2003. 
DOD anticipates that there will be approved spiral development programs 
to report in 2004.

Section 822: Independent Technology Readiness Assessments:

Requirements: This section added a requirement to section 804 
of the National Defense Authorization Act for Fiscal Year 2002 
(Public Law 107-107) that directed DOD to report by March of each year 
between 2003 and 2006 on the maturity of technology at the initiation 
of major defense acquisition programs. Each report is required to (1) 
identify any major acquisition program that entered system development 
and demonstration during the preceding calendar year with immature key 
technology that was not demonstrated in, at minimum, a relevant 
environment, as required by the new policy; (2) justify the 
incorporation of any key technology on an acquisition program that does 
not meet that requirement; (3) identify any instances that the Deputy 
Under Secretary of Defense for Science and Technology did not concur 
with the technology assessment and explain how the issue has been or 
will be resolved; (4) identify each case in which a decision was made 
not to conduct an independent technology readiness assessment for a 
critical technology on a major defense acquisition; and (5) explain the 
reasons for the decision each year through 2006.

DOD response: In March 2003, DOD reported that two programs entered 
system development and demonstration in 2002 with critical technologies 
that did not meet demonstration requirements and provided justification 
for them.[Footnote 8] DOD did not identify or report any cases where an 
independent technology readiness assessment was not conducted or where 
the Under Secretary disagreed with assessment findings.

Conclusions:

DOD can maximize its $1 trillion investment in new weapons over the 
next 6 years by ensuring effective implementation of the new 
acquisition policy. DOD's leaders have taken noteworthy steps by 
incorporating into the policy a framework that supports a knowledge-
based, evolutionary acquisition process, similar to one used by leading 
commercial companies to get successful outcomes. A framework is an 
important and significant step. DOD must now turn its attention to 
establishing controls. As leading companies have found, having clearly 
established controls to capture and use appropriate knowledge to make 
decisions at critical junctures is crucial for delivering affordable 
products as planned. DOD's policy addresses specific congressional 
requirements and includes some controls that leading companies use to 
capture knowledge at the start of a program. However, additional 
controls are needed to ensure that decisions made throughout product 
development are informed by demonstrated knowledge.

Recommendations for Executive Action:

DOD must design and implement necessary controls to ensure that 
appropriate knowledge is captured and used at critical junctures to 
make decisions about moving a program forward and investing more money. 
We recommend that the Secretary of Defense require additional controls 
for capturing knowledge at three key points--program launch, design 
readiness review for transitioning from system integration to system 
demonstration, and production commitment. The additional controls for 
program launch (milestone B) should ensure the capture of knowledge 
about the following:

* Cost and schedule estimates based on knowledge from a preliminary 
design using systems engineering tools.

The additional controls for transitioning from system integration to 
system demonstration (design readiness review) should ensure the 
capture of knowledge about the following:

* Completion of 90 percent of engineering drawings.

* Completion of subsystem and system design reviews.

* Agreement from all stakeholders that drawings are complete and the 
design is producible.

* Completion of failure modes and effects analysis.

* Identification of key system characteristics.

* Identification of critical manufacturing processes.

* Reliability targets and a reliability growth plan based on 
demonstrated reliability rates of components and subsystems.

The additional controls for the production commitment (milestone C) 
should ensure the capture of knowledge about the following:

* Completion of production representative prototypes.

* Availability of production representative prototypes to achieve 
reliability goal and demonstrate the product in an operational 
environment.

* Collection of statistical process control data.

* Demonstration that critical manufacturing processes are capable and 
in statistical control.

Because knowledge about technology, design, and manufacturing at 
critical junctures can lower DOD's investment risk, decisions that do 
not satisfy knowledge-based criteria should be visible and justified. 
Therefore, we also recommend that the Secretary of Defense document the 
rationale for any decision to move a program to the next stage of 
development without meeting the knowledge-based criteria, including 
those listed in the first recommendation. The responsible milestone 
decision authority should justify the decision in the program's 
acquisition decision memorandum and in a report to Congress.

Agency Comments and Our Evaluation:

DOD provided us with written comments on a draft of this report. The 
comments appear in appendix IV.

DOD partially concurred with our recommendation that the Secretary 
require additional controls for capturing knowledge at three key 
points: program launch, design readiness review for transitioning from 
system integration to system demonstration, and production. DOD stated 
that it agrees in principle with the advantages of using knowledge-
based controls at key points in the acquisition process to assess risk 
and ensure readiness to proceed into the next phase of the acquisition 
process. DOD believes the current acquisition framework includes the 
controls necessary to achieve effective results, but it will continue 
to monitor the process to determine whether others are necessary to 
achieve the best possible outcomes.

While we believe DOD's effort to establish a solid framework for 
evolutionary acquisitions is a giant step forward, our work has shown 
that a disciplined application of controls in the process is needed to 
implement the framework if better acquisition outcomes are to be 
achieved. DOD's policy does not include all the necessary controls to 
ensure a high level of product knowledge is attained and used for 
making decisions to move a program forward in the product development 
process. Leading product developers use additional controls, as listed 
in our first recommendation, to achieve the knowledge necessary to 
reduce risk to reasonable levels at critical junctures before making 
additional significant investments in product development. Simply 
monitoring the process may not be enough for DOD to achieve the best 
outcomes. Therefore, we are retaining our recommendation that the 
Secretary require additional controls at three critical points in the 
acquisition process.

DOD also partially concurred with our recommendation that the Secretary 
document in each program's acquisition decision memorandum and in a 
report to Congress the rationale for any decision to move a program to 
the next stage of development without meeting the knowledge-based 
criteria, including those described in the first recommendation. DOD 
agreed that it should record and be accountable for program decisions. 
Decision makers will continue to use the acquisition decision 
memorandum to document program decisions and the rationale for them. 
DOD did not concur with the need for a report outside the department. 
Because we believe strongly that knowledge-based criteria used to gauge 
a product's development progress at critical junctures can lower DOD's 
investment risks, we think it is important that decisions made without 
satisfying knowledge-based criteria be justified in a visible and 
transparent way to hold managers accountable for moving a program 
forward absent this knowledge. Therefore, we are retaining our 
recommendation for reporting the basis for decisions to move forward in 
a report to Congress.

Scope and Methodology:

We reviewed DOD's revised and past acquisition policies, DOD Directive 
5000.1, DOD Instruction 5000.2, and DOD 5000.2-R,[Footnote 9] which 
provide management principles and mandatory policies and procedures for 
managing acquisitions programs. We contacted an official in the Office 
of the Under Secretary of Defense for Acquisition, Technology, and 
Logistics who is responsible for the development of the policy to 
better understand its content. We also reviewed information from the 
Defense Acquisition University that provided educational material on 
the policies.

We reviewed the relevant sections of the Bob Stump National Defense 
Authorization Act for Fiscal Year 2003 and the accompanying Senate 
Armed Services Committee report to identify the requirements applicable 
to DOD's acquisition policy. We compared these requirements with DOD's 
responses to determine whether they have been addressed.

Finally, we used information from more than 10 GAO products that 
examine how commercial best practices can improve outcomes for various 
DOD programs. During the past 6 years, we have gathered information 
based on discussions and visits with the following companies:

:

3M; Boeing Commercial Airplane Group; Chrysler; Bombardier Aerospace; 
Ford Motor; Hughes Space and Communication; Motorola; Xerox; Hewlett-
Packard; Caterpillar; Cummins; General Electric Aircraft Engines; 
Toyota; Harris Semiconductor; Honda; Texas Instruments; John Deere; 
Varian Oncology Systems; Ethicon-Endo Surgery (division of Johnson & 
Johnson).

[End of table]

Although the approaches varied, these companies consistently applied 
the basic processes and standards in use. We compared this information 
with the acquisition framework and controls established by DOD's 
policy. We concentrated on whether the policy provides a framework for 
a knowledge-based, evolutionary process and the controls necessary to 
carry out this intent.

We conducted our review from April 2003 to September 2003 in accordance 
with generally accepted government auditing standards.

We are sending copies of this report to the Secretary of Defense; the 
Secretaries of the Air Force, Army, and Navy; and the Director of the 
Office of Management and Budget. We will also provide copies to others 
on request. In addition, the report will be available at no charge on 
the GAO Web site at http://www.gao.gov.

Please contact me at (202) 512-4841 if you have any questions 
concerning this report. Other key contributors to this report were 
Lily Chin, Chris DePerro, Matt Lea, Mike Sullivan, and Adam Vodraska.

Katherine V. Schinasi: 
Director, Acquisition and Sourcing Management:

Signed by Katherine V. Schinasi:

[End of section]

Appendix I: Section 802, Evolutionary Acquisition:

Section 802 of the Defense Authorization Act for Fiscal Year 2003 
required the Secretary of Defense to submit a report to Congress 
explaining how the Department of Defense (DOD) plans to meet certain 
statutory and regulatory requirements for acquisition programs 
following an evolutionary approach. In April 2003, the Secretary 
reported how these requirements were addressed in DOD's policy (such as 
in tables of statutory and regulatory information requirements 
contained in enclosure 3 of Instruction 5000.2). According to the 
report, DOD's policy requires that each program--including an increment 
of an evolutionary acquisition--have a milestone B decision to approve 
program initiation and to permit entry into systems development and 
demonstration. DOD's policy specifies the statutory and regulatory 
information necessary to support the decision. We examined the policy 
to ensure the statutes and regulations identified in section 802 were 
addressed. Table 3 provides a list of the statutory and regulatory 
requirements identified in section 802, a corresponding document and 
page number where the requirement appears in DOD's policy, and a 
description of the requirement from the policy.

Table 3: How DOD Policy Addresses Section 802's Statutory and 
Regulatory Requirements:

Section 802 requirements: Requirements of chapter 144 of title 10, 
United States Code: 

Section 802 requirements: Sec. 2430, major defense acquisition program 
defined; DOD policy reference examples: Department of Defense 
Instruction (DODI) 5000.2, enclosure 2, p. 16; Brief description from 
policy: Table E.2.T1 provides a description (criteria) and the decision 
authority by acquisition program category.

Section 802 requirements: Sec. 2431, weapons development and 
procurement schedules; DOD policy reference examples: Not 
referenced[A]; Brief description from policy: [Empty].

Section 802 requirements: Sec. 2432, Selected Acquisition Reports; DOD 
policy reference examples: DODI 5000.2, enclosure 3, p.19; Brief 
description from policy: Required at milestone B or program initiation 
and annually thereafter; end of quarter following milestone C decision; 
full-rate production decision. Also required when there is a baseline 
breach.

Section 802 requirements: Sec. 2433, unit cost reports; DOD policy 
reference examples: DODI 5000.2, enclosure 3, p. 19; Brief description 
from policy: Required on quarterly basis.

Section 802 requirements: Sec. 2434, independent cost estimates; 
operational manpower requirements; DOD policy reference examples: DODI 
5000.2, enclosure 6, p. 30 DODI 5000.2, enclosure 3, p. 19; Brief 
description from policy: Required at program initiation for ships (cost 
assessment only). Required at milestones B and C and full-rate 
production decision.

Section 802 requirements: Sec. 2435, baseline description; DOD policy 
reference examples: DODI 5000.2, enclosure 3, p. 19 DODI 5000.2, p. 8; 
Brief description from policy: Required at program initiation for 
ships. Required at milestones B and C and full-rate production 
decision. Program deviation report required immediately upon program 
deviation.

Section 802 requirements: Sec 2440, technology and industrial base 
plans; DOD policy reference examples: DODI 5000.2, enclosure 3, p. 19; 
Brief description from policy: Required at milestones B and C (part of 
acquisition strategy).

Section 802 requirements: Sec. 139, Director of Operational Test and 
Evaluation; DOD policy reference examples: Department of Defense 
Directive (DODD) 5000.1, p. 3 DODI 5000.2, enclosure 3 DODI 5000.2, 
enclosure 5, pp. 27-29; Brief description from policy: Cites Director 
of Operational Test and Evaluation as key official of defense 
acquisition system. Director responsible for assessing adequacy of 
operational tests and live fire tests and evaluating operational 
effectiveness, suitability, and survivability of systems.

Section 802 requirements: Sec. 181, Joint Requirements Oversight 
Council; DOD policy reference examples: DODD 5000.1, p. 3 DODI 5000.2, 
p. 4; Brief description from policy: Chairman of the Joint Chiefs of 
Staff, with assistance of Joint Requirements Oversight Council, 
responsible for assessing and providing advice regarding capability 
needs for defense acquisition programs. Chairman also responsible for 
validating and approving capabilities documents.

Section 802 requirements: Sec. 2366, major systems and munitions 
programs: survivability testing and lethality testing required before 
full-scale production; DOD policy reference examples: DODI 5000.2, 
enclosure 3, p. 19 DODI 5000.2, enclosure 5, p. 29 DODI 5000.2, p. 10; 
Brief description from policy: Live fire testing and reporting required 
for all covered systems. Strategy or live fire waiver and alternate 
plan required at milestone B. Live fire test and evaluation report 
required for full-rate production decision.

Section 802 requirements: Sec. 2399, operational test and evaluation of 
defense acquisition programs; DOD policy reference examples: DODI 
5000.2, enclosure 3, p. 18 DODI 5000.2, pp. 9-10 DODI 5000.2, enclosure 
5, pp. 27-28; Brief description from policy: Director of Operational 
Test and Evaluation shall determine operational effectiveness and 
suitability of system under realistic conditions. Beyond Low Rate 
Initial Production Report required at full-rate production decision. 
DOD may not conduct operational testing until Director of Operational 
Test and Evaluation approves test plan.

Section 802 requirements: Sec. 2400, low-rate initial production of new 
systems; DOD policy reference examples: DODI 5000.2, enclosure 3, p. 19 
DODI 5000.2, pp. 9-10; Brief description from policy: Low-rate initial 
production quantities will be determined by milestone B.

Section 802 requirements: DODD 5000.1; DOD policy reference examples: 
DODD 5000.1, pp. 1, 2; Brief description from policy: Policies in 
directive apply to all acquisition programs. Evolutionary acquisition 
strategies are preferred approach to satisfying operational needs.

Section 802 requirements: DODI 5000.2; DOD policy reference examples: 
DODI 5000.2, p. 1; Brief description from policy: Instruction applies 
to all defense technology projects and acquisition projects.

Section 802 requirements: Chairman of the Joint Chiefs of Staff 
Instruction 3170.01B[B]; DOD policy reference examples: DODI 5000.2, p. 
4; Brief description from policy: Chairman of Joint Chiefs of Staff 
provides advice through Instruction 3170.01. Capability documents 
required at concept decision and at milestones A, B, and C.

Section 802 requirements: Other provisions of law and regulations 
(including successor documents) that are applicable to such programs; 
DOD policy reference examples: DODI 5000.2, enclosure 3, pp. 18-22; 
Brief description from policy: Several other statutory, regulatory, and 
contract requirements are addressed in the policy.

Sources: Defense Authorization Act for Fiscal Year 2003, DOD, and GAO.

[A] Although the statutory requirement of 10 U.S.C., section 2431 is 
not specifically cited in the policy, the same summarized information 
is submitted to Congress in the Selected Acquisition Reports for the 
first quarter of a fiscal year as required by 10 U.S.C., section 2432. 
The requirement for Selected Acquisition Reports is addressed by DOD's 
acquisition policy. The statute concerning weapons development and 
procurement schedules requires the Secretary of Defense to submit 
budget justification documents regarding this information for each 
weapon system for which fund authorization is required (and for which 
procurement funds are requested in the budget) not later than 45 days 
after the President submits the budget to Congress.

[B] Chairman of the Joint Chiefs of Staff Instruction 3170.01B was 
revised and reissued June 24, 2003, as Joint Chiefs of Staff 
Instruction 3170.01C with an accompanying manual.

[End of table]

Section 802 also required DOD to report on its plans for addressing 
certain acquisition process issues regarding each increment of an 
evolutionary process. DOD reported on how it plans to establish and 
approve operational requirements and cost and schedule goals; meet 
requirements for operational and live fire testing; monitor cost and 
schedule performance; achieve interoperability; and consider total 
system performance and total ownership costs. We compared DOD's 
response with section 802's reporting requirements. As shown in table 
4, DOD was responsive to the 802 requirements.

Table 4: How DOD Responded to Section 802's Requirements Regarding 
Specific Matters for Each Increment of an Evolutionary Acquisition 
Process:

Section 802 requirements: "The manner in which the Secretary plans to 
establish and approve, for each increment of an evolutionary 
acquisition process: 

Section 802 requirements: "operational requirements;" DOD 
response: "Operational Requirements: Each program is required to have 
documented, approved operational requirements in accordance with 
authorized Joint Staff procedures. For evolutionary acquisition 
programs, the requirements documents are typically time-phased and 
specify the capability expected of each increment."; Policy reference: 
Capability development document, including key performance parameters, 
required at milestone B or program initiation (DODI 5000.2, p. 7, and 
enclosure 3, p. 20).

Section 802 requirements: "cost and schedule goals."; DOD response: 
"Cost and Schedule Goals: At program initiation, each program and 
program increment is required to have an Acquisition Program Baseline 
approved by the Milestone Decision Authority (MDA). The Acquisition 
Program Baseline includes cost and schedule goals."; Policy reference: 
Acquisition program baseline required at milestone B or program 
initiation (DODI 5000.2, p. 8, and enclosure 3, p. 19).

Section 802 requirements: "The manner in which the Secretary plans, for 
each increment of an evolutionary acquisition process:" 

Section 802 requirements: "to meet requirements for operational testing 
and live fire testing;"; DOD response: "At program initiation, each 
program or program increment must have a Test and Evaluation Master 
Plan (TEMP) approved by the Director, Operational Test and Evaluation. 
The TEMP includes requirements for operational and live fire testing."; 
Policy reference: Test and Evaluation Master Plan required at milestone 
B or program initiation (DODI 5000.2, enclosure 3, p. 21, and enclosure 
5, p. 25).

Section 802 requirements: "to monitor cost and schedule performance; 
and"; DOD response: "Progress against cost and schedule goals [for each 
increment] is addressed via automated reporting systems at both the 
Office of Secretary of Defense staff level and at the Service staff 
level, and by reviews conducted in the context of the acquisition 
oversight model."; Policy reference: DOD's policy contains an enclosure 
on resource estimation (DODI 5000.2, enclosure 6, pp. 30-31). Also, 
several reporting requirements address monitoring cost and schedule 
performance such as acquisition program baselines and selected 
acquisition reports (DODI 5000.2, enclosure 3, pp. 18-21).

Section 802 requirements: "to comply with laws requiring reports to 
Congress on results testing and on cost and schedule performance."; DOD 
response: "DoD acquisition policy requires independent assessment by 
the operational test authority prior to release of each successive 
increment to the user. All reports by statute will be submitted."; 
Policy reference: The service shall perform an independent operational 
assessment prior to release of each successive increment to the user 
(DODI 5000.2, enclosure 5, p. 29). Also, several statutory reports are 
listed in the policy addressing testing and cost and schedule 
performance (DODI 5000.2, enclosure 3, pp. 18-21).

Section 802 requirements: "The manner in which the Secretary plans to 
ensure that each increment of an evolutionary acquisition process is 
designed:"

Section 802 requirements: "to achieve interoperability within and among 
United States forces and United States coalition partners; and"; DOD 
response: "Each increment of an evolutionary acquisition program is 
required to have an Acquisition Program Baseline, approved by the MDA, 
which includes an Interoperability key performance parameter."; Policy 
reference: Acquisition program baseline required at milestone B or 
program initiation (DODI 5000.2, p. 8, and enclosure 3, p. 19).

Section 802 requirements: "to optimize total system performance and 
minimize total ownership costs by giving appropriate consideration to: 
"logistics planning;"; "manpower, personnel, and training;"; "human, 
environmental, safety, occupational health, accessibility, 
survivability, operational continuity and security factors;"; 
"protection of critical program information; and"; "spectrum 
management"; DOD response: "Each increment of an evolutionary 
acquisition program is required to have an acquisition strategy, 
approved by the MDA, that addresses [where applicable]: logistics 
planning; manpower, personnel and training; human, environmental, 
safety, occupational health; accessibility (human), survivability, 
operational continuity (as required by requirements document), security 
factors; critical program information; and spectrum management. These 
factors are taken into account as the Department of Defense considers 
total system performance and total ownership costs."; Policy reference: 
Acquisition strategy required at milestone B or program initiation 
(DODI 5000.2, p. 7, and enclosure 3, p. 20).

Sources: Defense Authorization Act for Fiscal Year 2003, DOD, and GAO.

[End of table]

[End of section]

Appendix II: Section 803, Spiral Development:

Section 803 of the Defense Authorization Act for Fiscal Year 2003 
authorized the Secretary of Defense to conduct major defense 
acquisition programs as spiral development programs. However, the 
section placed a limitation on these programs. It stated that a 
research and development program for a major acquisition may not be 
conducted as a spiral development program unless the Secretary of 
Defense or authorized high-level designee gives approval. The section 
requires the Secretary of Defense to issue guidance for the 
implementation of such programs to address appropriate processes for 
ensuring the independent validation of exit criteria being met, the 
operational assessment of fieldable prototypes, and the management of 
these types of programs.

DOD responded to these requirements principally by incorporating into 
the acquisition policy the requirement for a technology development 
strategy. This strategy is a prerequisite for a project to enter the 
technology development phase of the acquisition process, or 
milestone A. Table 5 compares the spiral development plan requirements 
in the act with the technology development strategy requirements in 
DOD's May 2003 acquisition policy.

Table 5: How DOD Policy Addresses Section 803's Requirements:

[See PDF for image]

Sources: Defense Authorization Act for Fiscal Year 2003, DOD, and GAO.

[End of table]

As shown in the table, DOD's policy generally responded to the 
requirements in the act concerning guidance for implementation of 
spiral development programs. While the policy includes a technology 
development strategy that requires a test plan to ensure the goals and 
exit criteria for the first technology spiral demonstration are met and 
an independent operational assessment for the release of each product 
increment to the user, it is unclear what the process is for 
independently validating that cost, schedule, and performance exit 
criteria have been. However, DOD stated that the milestone decision 
authority provides independent validation that exit criteria have been 
met as part of DOD's milestone approval process. Section 803 also 
requires that a spiral development plan include "[s]pecific cost, 
schedule, and performance parameters, including measurable exit 
criteria, for the first spiral to be conducted." DOD's policy 
substituted "parameters" for "goals" and did not use the term 
"measurable" in describing the required exit criteria.

Finally, section 803 requires the Secretary of Defense to submit to 
Congress by September 30 yearly from 2003 through 2008 a status report 
on each spiral development program. The report is to include 
information on unit costs for the projected prototypes. As of October 
23, 2003, DOD's report on the status of each program applying spiral 
development was still in draft and not yet submitted. DOD's current 
draft report states that there are no research and development programs 
that have been approved as spiral development programs as of September 
30, 2003. Section 803 requirements were implemented in DOD Instruction 
5000.2, which was effective in May 2003. DOD anticipates that there 
will be approved spiral development programs to report in 2004.

[End of section]

Appendix III: Section 804, Technology Maturity, and Section 822, 
Independent Technology Readiness Assessments:

Section 804 of the Defense Authorization Act for Fiscal Year 2002 
required DOD to report on the maturity of technology at the initiation 
of major defense acquisition programs. The act directed DOD to report 
by March 1 of each year between 2003 and 2006 on a requirement in DOD's 
policy that technology must have been demonstrated in a relevant 
environment (or, preferably, in an operational environment) to be 
considered mature enough to use for product development in systems 
integration. Each report is required to (1) identify any major 
acquisition program that entered system development and demonstration 
during the preceding calendar year with immature key technology that 
was not demonstrated in, at minimum, a relevant environment, as 
required by the new policy; (2) justify the incorporation of any key 
technology on an acquisition program that does not meet that 
requirement; (3) and identify any instances that the Deputy Under 
Secretary of Defense for Science and Technology did not concur and 
explain how the issue has been or will be resolved, including 
information on the use of independent readiness assessments. Section 
822 of the Defense Authorization Act for Fiscal Year 2003 amended 
section 804 by adding a requirement that the Secretary of Defense 
identify each case in which an authoritative decision has been made 
within DOD not to conduct an independent technology readiness 
assessment for a critical technology on a major defense acquisition 
program and explain the reasons for the decision. On March 18, 2003, 
DOD submitted its first report. Table 6 shows the specific requirements 
for the report and DOD's response.

Table 6: How DOD Responded to Section 804 and Section 822 Requirements:

Reporting requirements: Section 804: "identify each case in which a 
major defense acquisition program entered system development and 
demonstration during the preceding calendar year and into which key 
technology has been incorporated that does not meet the technological 
maturity requirement … and provide a justification for why such key 
technology was incorporated."[A]; DOD's response: DOD reported two 
programs (Joint Tactical Radio System Cluster 1 and Composite Health 
Care System II) that entered system development and demonstration with 
key technologies that did not meet the technological maturity 
requirement. While DOD did not specifically identify all the 
technologies for these programs that did not meet the requirements, it 
did provide its justification for why the technologies were 
incorporated.

Reporting requirements: Section 804: "identify any determination of 
technological maturity with which the Deputy Under Secretary of Defense 
for Science and Technology did not concur and explain how the issue has 
been or will be resolved."; DOD's response: DOD reported that, in all 
cases, the Deputy Under Secretary of Defense for Science and Technology 
concurred with the technology readiness assessment of the program 
manager and the milestone decision authority.

Reporting requirements: Section 822: "identify each case in which an 
authoritative decision has been made within the Department of Defense 
not to conduct an independent technology readiness assessment for a 
critical technology on a major defense acquisition program and explain 
the reasons for the decision."; DOD's response: DOD did not report on 
or identify any cases.

Sources: National Defense Authorization Acts for Fiscal Years 2002 and 
2003, DOD, and GAO.

[A] Technology must have been demonstrated in a relevant environment 
(or, preferably in an operational environment) to be considered mature 
enough to use for product development in systems integration.

[End of table]

[End of section]

Appendix IV: Comments from the Department of Defense:

OFFICE OF THE UNDER SECRETARY OF DEFENSE:

ACQUISITION, TECHNOLOGY AND LOGISTICS:

3000 DEFENSE PENTAGON WASHINGTON, DC 20301-3000:

October 22, 2003:

Ms. Katherine Schinasi:

Director, Acquisition and Sourcing Management U.S. General Accounting 
Office:

441 G Street, N.W. Washington, D.C. 20548:

Dear Ms. Schinasi:

This is the Department of Defense (DOD) response to the GAO draft 
report, DEFENSE ACQUISITIONS: DoD's Revised Policy Emphasizes Best 
Practices, But More Controls Are Needed, dated September 26, 2003 (GAO 
Code 120214/GAO-04-53). The Department of Defense partially concurs 
with the recommendations in the report. We have enclosed comments which 
explain this position.

Sincerely,

Signed for: 

Deidre A. Lee: 
Director, Defense Procurement and Acquisition Policy:

Enclosure: As stated:

GAO DRAFT REPORT-DATED SEPTEMBER 26, 2003 GAO CODE 120214/GAO-04-53:

DEFENSE ACQUISITIONS: DOD'S REVISED POLICY EMPHASIZES BEST PRACTICES, 
BUT MORE CONTROLS ARE NEEDED:

DEPARTMENT OF DEFENSE COMMENTS TO THE RECOMMENDATIONS:

RECOMMENDATION 1: The GAO recommended that the Secretary of Defense 
require additional controls for capturing knowledge at three key 
points-program launch, design readiness review for transitioning from 
system integration to system demonstration, and production commitment. 
(p. 11/GAO Draft Report):

The additional controls for program launch (milestone B) should ensure 
the capture of knowledge about the following:

* Cost and schedule estimates based on knowledge from a preliminary 
design using systems engineering tools.

The additional controls for the moving from system integration to 
system demonstration (design readiness review) should ensure the 
capture of knowledge about the following: 

* Completion of 90 percent of engineering drawings.

* Completion of subsystem and system design reviews.

* Agreement from all stakeholders that drawings are complete and the 
design is producible.

* Completion of failure modes and effects analysis.

* Identification of key system characteristics.

* Identification of critical manufacturing processes.

* Reliability targets and a reliability growth plan based on 
demonstrated reliability rates of components and subsystems.

The additional controls for the production commitment (milestone C) 
should ensure the capture of knowledge about the following:

* Completion of production representative prototypes.

* Availability of production representative prototypes to achieve 
reliability goal and demonstrate the product in an operational 
environment.

* Collection of statistical process control data.

* Demonstration that critical manufacturing processes are capable and in 
statistical control.

DOD RESPONSE: Partially Concur. The Department of Defense agrees in 
principle with the advantages of using knowledge-based controls at key 
points in the acquisition process to assess risk and ensure readiness 
to proceed into the next phase of the acquisition process. The 
acquisition framework was recently redesigned to include the controls 
we consider necessary to achieve effective program results, including, 
for example, assessments of technical and design readiness. We will 
continue to monitor the acquisition process to assess the effectiveness 
of these controls, and determine whether others are necessary to 
achieve the best possible outcomes.

RECOMMENDATION 2: The GAO recommended that the Secretary of Defense 
document the rationale for any decision to move a program to the next 
stage of development without meeting the knowledge-based criteria, 
including those listed in the first recommendation. The responsible 
acquisition executive should justify the decision in the program's 
acquisition decision memorandum and in a report to Congress. (p. 12/GAO 
Draft Report):

DOD RESPONSE: Partially concur. The Department of Defense agrees that 
we should be accountable for program decisions and appropriately record 
the considerations in moving from one stage of development to the next. 
Milestone Decision Authorities will continue to employ the Acquisition 
Decision Memorandum (ADM) to document program decisions and their 
rationale. We do not concur with the need for a report outside the 
Department.

[End of section]

Related GAO Products:

Best Practices: Setting Requirements Differently Could Reduce 
Weapon Systems' Total Ownership Costs. GAO-03-57. Washington, D.C.: 
February 11, 2003.

Best Practices: Capturing Design and Manufacturing Knowledge 
Early Improves Acquisition Outcomes. GAO-02-701. Washington, D.C.: 
July 15, 2002.

Defense Acquisitions: DOD Faces Challenges in Implementing Best 
Practices. GAO-02-469T. Washington, D.C.: February 27, 2002.

Best Practices: Better Matching of Needs and Resources Will Lead 
to Better Weapon System Outcomes. GAO-01-288. Washington, D.C.: 
March 8, 2001.

Best Practices: A More Constructive Test Approach Is Key to 
Better Weapon System Outcomes. GAO/NSIAD-00-199. Washington, D.C.: 
July 31, 2000.

Defense Acquisition: Employing Best Practices Can Shape Better Weapon 
System Decisions. GAO/T-NSIAD-00-137. Washington, D.C.: 
April 26, 2000.

Best Practices: DOD Training Can Do More to Help Weapon System Program 
Implement Best Practices. GAO/NSIAD-99-206. Washington, D.C.: 
August 16, 1999.

Best Practices: Better Management of Technology Development Can Improve 
Weapon System Outcomes. GAO/NSIAD-99-162. Washington, D.C.: July 30, 
1999.

Defense Acquisitions: Best Commercial Practices Can Improve Program 
Outcomes. GAO/T-NSIAD-99-116. Washington, D.C.: March 17, 1999.

Defense Acquisition: Improved Program Outcomes Are Possible. GAO/T-
NSIAD-98-123. Washington, D.C.: March 17, 1998.

Best Practices: DOD Can Help Suppliers Contribute More to Weapon System 
Programs. GAO/NSIAD-98-87. Washington, D.C.: March 17, 1998.

Best Practices: Successful Application to Weapon Acquisition Requires 
Changes in DOD's Environment. GAO/NSIAD-98-56. Washington, D.C.: 
February 24, 1998.

Best Practices: Commercial Quality Assurance Practices Offer 
Improvements for DOD. GAO/NSIAD-96-162. Washington, D.C.: 
August 26, 1996.

FOOTNOTES

[1] S. Rept. No. 108-46, Report of the Senate Armed Services Committee 
accompanying S. 1050, National Defense Authorization Act for Fiscal 
Year 2004, at page 346 (May 13, 2003).

[2] As used here, the term "regulatory requirements" refers to policies 
governing DOD's acquisition system.

[3] DOD Directive 5000.1, The Defense Acquisition System, describes the 
management principles for DODís acquisition programs DOD Instruction 
5000.2, The Operation of the Defense Acquisition System, outlines a 
framework for managing acquisition programs. Collectively, these are 
known as the 5000 series.

[4] Program elements of the ballistic missile defense program enter the 
formal DOD acquisition cycle at milestone C (production commitment) and 
are subject to the 5000 series from that point on. To use the 
streamlined process of the National Security Space Acquisition Policy, 
a Space System Program Director/Program Manager must request that the 
DOD Space Milestone Decision Authority (the Under Secretary of the Air 
Force) grant a waiver and an exemption to the processes and procedures 
described in DOD Instruction 5000.2 (the waiver authority does not 
include DOD Directive 5000.1). Notwithstanding these policy exceptions, 
statutory requirements for major defense acquisition programs continue 
to apply to missile defense and space programs.

[5] A spiral development program is defined in section 803 of the 
Defense Authorization Act for Fiscal Year 2003 as a research and 
development program conducted in discrete phases or blocks, each of 
which will result in the development of fieldable prototypes and will 
not proceed into acquisition until specific performance parameters, 
including measurable exit criteria, have been met.

[6] The milestone decision authority is typically the DOD component 
acquisition executive or designee, or for certain large programs, the 
head of the component or the Under Secretary of Defense for 
Acquisition, Technology, and Logistics.

[7] Section 803 authorized the Secretary of Defense to delegate 
authority to approve a spiral development plan to the Under Secretary 
of Defense for Acquisition, Technology, and Logistics or to the senior 
acquisition executive of the military department or defense agency 
concerned. The authority may not be delegated further.

[8] The two programs were the Composite Health Care System II and the 
Joint Tactical Radio System, Cluster 1.

[9] DOD 5000.2-R was canceled and replaced with the Interim Defense 
Acquisition Guidebook.

GAO's Mission:

The General Accounting Office, the investigative arm of Congress, 
exists to support Congress in meeting its constitutional 
responsibilities and to help improve the performance and accountability 
of the federal government for the American people. GAO examines the use 
of public funds; evaluates federal programs and policies; and provides 
analyses, recommendations, and other assistance to help Congress make 
informed oversight, policy, and funding decisions. GAO's commitment to 
good government is reflected in its core values of accountability, 
integrity, and reliability.

Obtaining Copies of GAO Reports and Testimony:

The fastest and easiest way to obtain copies of GAO documents at no 
cost is through the Internet. GAO's Web site ( www.gao.gov ) contains 
abstracts and full-text files of current reports and testimony and an 
expanding archive of older products. The Web site features a search 
engine to help you locate documents using key words and phrases. You 
can print these documents in their entirety, including charts and other 
graphics.

Each day, GAO issues a list of newly released reports, testimony, and 
correspondence. GAO posts this list, known as "Today's Reports," on its 
Web site daily. The list contains links to the full-text document 
files. To have GAO e-mail this list to you every afternoon, go to 
www.gao.gov and select "Subscribe to e-mail alerts" under the "Order 
GAO Products" heading.

Order by Mail or Phone:

The first copy of each printed report is free. Additional copies are $2 
each. A check or money order should be made out to the Superintendent 
of Documents. GAO also accepts VISA and Mastercard. Orders for 100 or 
more copies mailed to a single address are discounted 25 percent. 
Orders should be sent to:

U.S. General Accounting Office

441 G Street NW,

Room LM Washington,

D.C. 20548:

To order by Phone: 	

	Voice: (202) 512-6000:

	TDD: (202) 512-2537:

	Fax: (202) 512-6061:

To Report Fraud, Waste, and Abuse in Federal Programs:

Contact:

Web site: www.gao.gov/fraudnet/fraudnet.htm E-mail: fraudnet@gao.gov

Automated answering system: (800) 424-5454 or (202) 512-7470:

Public Affairs:

Jeff Nelligan, managing director, NelliganJ@gao.gov (202) 512-4800 U.S.

General Accounting Office, 441 G Street NW, Room 7149 Washington, D.C.

20548: